WORKSHOP TECHNOLOGY

(DJJ10033)

CHAPTER 1 : HAND TOOLS

Course Learning Outcomes (CLO) 1 :
Apply the knowledge of basic mechanical
components and equipment, hand tools and
measuring equipment in workshop technology
CONTENT

1) Hand tools in fitting work

2) Use of tools
3) Measurement
1) HAND TOOLS IN FITTING WORKS
Subtopic covered :-
a) Marking out / lay out
b) Procedure of marking out /lay out
c) Marking tools :-
Scriber , centre punch , divider , surface
plate and procedures to draw a circle,
lines, curve and etc
1) HAND TOOLS IN FITTING WORKS
• TOOLS
equipment or instruments that give helps in
the production of a product or any related
activities
• FITTING WORKS
manufacturing process refer to assembly parts
together and removing metal to secure
necessary fit.
• The Important of hand tools in fitting workshop for minor
operations to be performed to finish the job by hand.
1) HAND TOOLS IN FITTING WORKS
a) Marking Out/Layout
• Marking out - Put a mark on a workpiece
• Layout - Marking out arrangement

The process of transferring a design or pattern to

a workpiece, as the first step in the
manufacturing process

Noted :- Very important to know how much to cut or

scrap the workpiece
1) HAND TOOLS IN FITTING WORKS
b) Procedure of Marking Out/Layout
i. Clean a sheet of metal with sand paper / brush to ensure
the mark made will be visible and unambiguous.

ii. Establish a datum point and datum lines on the metal.

Check the straightness with
the ruler by holding one
against the other and
holding them up to the light.

iii. File a second edge at right

angles to the first. Check with
the set square.
1) HAND TOOLS IN FITTING WORKS
b) Procedure of Marking Out/Layout
iv. The right angled corner is zero point or datum and the
two edges is datum lines
v. Plan the sequence regarding to the main outline. All
measurements from datum.
vi. Marks the initial point lightly and straight line or radius
for any arc by referring to the datum line.
1) HAND TOOLS IN FITTING WORKS
b) Procedure of Marking Out/Layout
iv. Make a small mark approximately at each end of the line
to be drawn by using the set square or divider and
produce the line by referring to the figure/drawing.
v. Check the measurement after completes the marking out
process.
1) HAND TOOLS IN FITTING WORKS
c) Marking Tools
Scriber [Penggarit]

Function ;
mark the line on the workpiece
1) HAND TOOLS IN FITTING WORKS
c) Marking Tools
Center Punch [Penebuk
Pusat]
Function - mark the
point before drilling
process
1) HAND TOOLS IN FITTING WORKS
c) Marking Tools
Divider
Function - Scribe arcs or circles
& transfers distance of
measurement to a ruler.
1) HAND TOOLS IN FITTING WORKS
c) Marking Tools
Divider
Procedures to draw a circle
and curve :
i. Locate one leg in first
major division.
ii. Adjust the other leg
to click into required
division plus one
major division.
iii. Do not punch mark
locates leg of dividers
when scribing arcs
and circles.
1) HAND TOOLS IN FITTING WORKS
c) Marking Tools
Surface Plate
Function - instrument for
measuring, transferring, or
marking off distance.
2) USED TOOLS
a) Testing tool
b) Hack saw
c) Files and filling works
d) Hammer
e) Chisel
f) Taps and dies
2) USED TOOLS
a) Testing Tools
Function - Tools used to
check, test and verify the
workpieces are marked
out / laid out according to
the specification required.
L Square
(Straightness,
perpendicularity and etc).

Types of Straight Edge

2) USED TOOLS
b) Hack Saw
Function - To cut metal and for cutting away waste parts of
the workpiece.
2) USED TOOLS
b) Hack Saw
• Sixty strokes per minute generally be using in the
metalwork room.
• Blade: Manufactured from high carbon steel, durable
steel, tungsten alloy steel and molybdenum alloy steel.
2) USED TOOLS
b) Hack Saw
Blade classification.
Teeth per 25mm Use

14 Soft thick materials. Alluminium, Copper, Mild Steel

General use. Soft materials in thin sections. Hard materials

18
in thick sections.
24 Thin section hard materials.

32 Very thin materials such as thin tubing and sheet metal.

2) USED TOOLS
b) Hack Saw
Procedure to replace hack saw blade ;
1. Loosen up the wing nuts and remove
the blade from frame
2. Take the new blade and install to the
frame in the right way and right
direction of the blade teeth.
3. Tighten wing nuts appropriately. Make
sure the blade not to tense or slack.
4. Selecting the correct blade for the
material to be cut is important when
setting up a hacksaw.
5. Selecting the correct number of teeth
per inch (25 mm) is also important.
2) USED TOOLS
b) Hack Saw
Causes of hack saw blades breakage ;
• Improper pressure on the job.
• Pointing of blade teeth in a wrong direction.
• Improper tension in the blade.
• Blade used unrequired specification.
• Blade or work piece not held properly.

** High Speed Steel (HSS) blades are used for tough, resistant materials whilst
High Carbon Steel blades are for general cutting.
** The general rule is that at least three teeth should extend across the surface of
the material to be cut.
2) USED TOOLS
b) Hack Saw
Safety precaution and procedure to prevent accidents:
1. Clamp the workpiece into a suitable clamping device
rigidly and securely.
2. Make sure the blade teeth are in correct position.
3. Start sawing with a slow motion first and start constant
sawing when mark appears on the workpiece. A good
stroke would be 60 strokes per minute.
4. During sawing put a pressure and push onto the frame.
5. When sawing is coming to an end, hold the suspended
part with a hand.
2) USED TOOLS
c) Files & Filling Works
Function - To cut fine amount of material from workpiece.

File Grades
Depends on how fine its teeth and the range between
teeth/cuts.
2) USED TOOLS
c) Files & Filling Works
Cuts Cross Cut /
Double Cut

Single
Cut

Grater
Cut

Dreadnought Cut
2) USED TOOLS
c) Files & Filling Works
Types and shapes of files and its uses

1. Flat Files : general use.

2. Equaling / Hand Files : flat finishing

2) USED TOOLS
c) Files & Filling Works
Types and shapes of files and its uses

3. Half round ring files : touch up the finished parts.

4. Round Files / Rat Tail Files : touch up the finished parts

2) USED TOOLS
c) Files & Filling Works
Types and shapes of files and its uses

5. Square Files : enlarge a square hole roughly. Also use to

files groove and channel.

6. Triangular files : Use to cutting angles less than 90 degree

and files sharp triangle and cleaning angled corner.
2) USED TOOLS
c) Files & Filling Works
Types and shapes of files and its uses

7. Pillar Files : files in narrow slot or gap.

8. Knife files : sharpen saw blade teeth and other cutting

tools teeth.
2) USED TOOLS
c) Files & Filling Works
Types and shapes of files and its uses

9. Needle Files Needle files are available in a set of files. One

set consist 4 to 12 types of files. Use to finishing work after
parts finished machining. The sizes range are 100mm,
140mm and 160mm
2) USED TOOLS
c) Files & Filing Works
Method of filling
Cross filing - When the file is pushed Draw filing - When the file is pushed
across the surface to be filed from across the surface from one edge of
tip to handle. the file to the other. This results in a
smoother cut.
2) USED TOOLS
c) Files & Filing Works
Pinning and ways to avoid pinning
 The file teeth is clogging with pins, which is material shavings .It will not only
affect the filing work as the files lose ability to cut but will scratch the work
piece surface.
 To avoid pinning, apply turpentine or rub chalk to the files
2) USED TOOLS
c) Files & Filing Works
Safety procedures in filing
1. Don’t use a file with no a handle.
2. Don’t use a file as meddle or hammer. File is a
hardered tool which can snap simply.
3. Use a file card to remain the file clean and free of
chips.
4. Use the right files based on work piece material.
Files that has fine teeth/cuts is used for harder
material. Do not use files for other work than filing.
5. Use rough grade files first and smooth grade files
for finishing.
6. Use file card brush to clean up the files. Avoid files
from oil and water as oil will cause a slippage during
filing and water will cause corrosive.
2) USED TOOLS
c) Files & Filing Works
Safety procedures in filing
1. Don’t use a file with no a handle.
2. Don’t use a file as meddle or hammer. File is a
hardered tool which can snap simply.
3. Use a file card to remain the file clean and free of
chips.
4. Use the right files based on work piece material.
Files that has fine teeth/cuts is used for harder
material. Do not use files for other work than filing.
5. Use rough grade files first and smooth grade files
for finishing.
6. Use file card brush to clean up the files. Avoid files
from oil and water as oil will cause a slippage during
filing and water will cause corrosive.
2) USED TOOLS
d) Hammer
Function : deliver an impact to part
2) USED TOOLS
d) Hammer
Types of Hammer and its uses
Ball peen : used to peen riveted or welded
material.

Straight peen : used for the works that

cannot be done by the ball peen hammer.

Cross peen : used for the works that cannot be done by

the ball peen or straight peen hammer.

Claw Hammer : The most popular hammer for

general work, available with a wooden (often
hickory), glass-fibre or steel handle; with or without
rubber grip.
2) USED TOOLS
d) Hammer
Types of Hammer and its uses
Soft Faced Hammer (mallet):
 Made from soft metals like copper, aluminum or other
materials such as plastic / rubber.
Wood Mallet
 Used for hammering finished jobs and for aligning jobs
on a machine.
 Used to driving tools such as chisel, or punch and
bending thin sheets in sheet metal work. Copper Mallet

Aluminium & Plastic Mallet Rubber Mallet Plastic Mallet

2) USED TOOLS
d) Hammer
Types of Hammer and its uses

Rubber mallet

Sheet metal forming

2) USED TOOLS
d) Hammer
The safety procedure in using hammer
 Make sure the hammer is on
hold firmly.
 Workpiece should be tied
securely in a vise during
tapping.
 During the process of knocking,
make sure your friends are far
away from our workshops in
order to avoid things that are
not wanted there.
2) USED TOOLS
e) Chisel
Function :
 To carve (mengukir) and cut metal.
 To remove waste metal from workpiece.
Parts of flat chisel
2) USED TOOLS
e) Chisel
Types and shapes of chisels and its uses
 Flat chisel : shearing thin stock  Diamond point chisel : Can be
or for cutting out sheet metal used for cutting into sharp internal
on a chipping block. corners.
2) USED TOOLS
e) Chisel
Types and shapes of chisels and its uses
 Cross cut chisel : Used where a  Half round chisel : Often used for
narrow groove is required such cutting oil grooves and "cleaning
as a key-way. up" corners.
2) USED TOOLS
e) Chisel
Material and cutting angle
Cape chisel Edge round chisel

Horizontal tip chisel Diamond tip point

Edge round Nose chisel

2) USED TOOLS
e) Chisel
Types and shapes of chisels and its uses

Metal Angle
Steel 70˚
Cast iron 60˚
Mild steel 60˚-70˚
Brass 45˚- 70˚
Copper 45˚
Aluminium 30˚
2) USED TOOLS
e) Chisel
The disadvantages of mushroom head chisel

 Ragged edge may fly off injure someone when it struck with the hammer
2) USED TOOLS
e) Chisel
How to use chisel?
1. Hold the work piece in place securely or rigidly.
(Clamp/vise/on an anvil-depends on situation).
2. Hold the chisel body with the cutting edge on
the mark. Make sure hands are free from oily
condition that will cause slippage during
chiseling.
3. Strike the chisel a light blow with the hammer,
and then examine the chisel mark on the work
to make certain that the cut is at the desired
point.
5. Drive the chisel into the work with vigorous
blows. The last few strokes, however, should be
made lightly in order to avoid unnecessary
damage to the supporting surface.
2) USED TOOLS
f) Tap & Dies
Parts Function
Taps and To create screw threads
die (threading)
To cut female portion
Taps [internal threads] of
mating pair (nut)
To cut male portion
Die [external threads] of
mating pair (bolt)
Screw threads
2) USED TOOLS
f) Tap & Dies
Terminologies
i. Through hole : the taper tap alone will do the work [the processing of
tapping begins with forming (usually by drilling) and slightly].
ii. Blind hole : the plug tap must be used finally and the chips knocked out of
the hole from time to time.
iii. Tap drill size [TD] = Major Diameter (MD) – Depth of the thread [pitch]

The tapping drill [TD] can be calculated by subtracting the pitch from the
diameter of the thread.
Eg for an M10x1.50 thread

Tapping Drill [TD] = MD – pitch = 10-1.50mm = 8.50 mm.

2) USED TOOLS
f) Tap & Dies
Types of Taps
I. Taper Tap : A taper tap is the first Tap wrenches
tap used in a tapping sequence
when tapping blind holes.
II. Intermediate/Second Tap : Tapered
threads typically ranges from 2 to 3
and it has tapered cutting edges,
which assist in aligning and starting
the tap into an untapped hole. It is
used right after taper tap.
III. Plug / Bottoming / Finisher Tap : A
bottoming tap is usually used to cut
threads in a hole that has already
been partially threaded using one of
the more tapered types of tap.
2) USED TOOLS
f) Tap & Dies
Lubrication for taps and die work
Material Lubrication
Mild steel Sulphur base oil
Bronze or copper Parafin / lard oil / whale oil
Aluminium Paraffin
Cast iron, brass None

Taps breakage reasons

 Did not follow the sequence of tap usage. Not use taper tap first.
 Force tap continuously tapping without reverse it back after half turn of the
tap.
 Too much pressure applied onto the tap during tapping.
 Does not use lubricants & not remove chips.
2) USED TOOLS
f) Tap & Dies
How to use the tap and dies ???
i. Drill a hole equal to the core diameter of the thread.
ii. Taper tap is fixed in the tap wrench and screwed
into the hole. Before start tapping, the screw
position must be adjusted until it stands square with
the tap surface of the work piece.
iii. Apply a little whale oil on the tap for all materials
except cast iron. Lubrication improves the surface
finish of threads whereas cast iron is self lubricating.
iv. Start the cutting action by turning the wrench
clockwise keeping in mind that tap is not turned
continuously but after every half turn it should be
reversed slightly to clear the threads.
v. Proceed till the taper tap is through the hole.
2) USED TOOLS
f) Tap & Dies
Types of dies
i. Die Nuts : Made for cleaning up damaged threads, have no split for resizing
and are made from a hexagonal bar so that a wrench or shifter spanner can
be used to turn them. Die nuts cannot be used to cut new threads.
ii. Circular split die : there are three adjusting screws but the adjustment is only
slight. The middle screw, which is pointed, forces the split open and the two
side screws are for closing the die.
2) USED TOOLS
f) Tap & Dies
How to use die for external threading ??
1. When starting to cut an external thread the die
should be "open", i.e. with the center screw
tight; also the side screws must be screwed
down to prevent any tendency lore the die to
twist.
2. A cylindrical blank, which is usually slightly less
than the required diameter, is machined with a
taper (chamfer) at the threaded end. This
chamfer allows the die to ease onto the blank
before it cuts a sufficient thread to pull itself
along.
3. Use a lubricant as for tapping and keep the die
"square" to the rod.
2) USED TOOLS
f) Tap & Dies
How to use die for external threading ??
1. Reverse the die a little from time to time to
break the chips.
2. After the first cut try the thread in the tapped
hole. If it is too tight take another cut with the
dies after slackening the center screw and
tightening the outside ones.
3) MEASUREMENT
a) Measurement tools
b) Micrometers
c) Vernier calliper
Vernier caliper
a) Measurement Tools

Steel ruler

Tape measure

External callipers Internal callipers

Angel-L Squre Ruler Micrometer

3) MEASUREMENT
b) Micrometer - Types of Micrometer
Types Function Figure
measure external
Outside/
dimensions such as the
external
outside diameter of an
Micrometer
object

measure inside dimensions

Inside
like the inside diameter of a
Micrometer
hole or tube

Depth measure the depths of

Micrometer holes, slots and steps.
3) MEASUREMENT
b) Micrometer - Parts of External Micrometer

1. Frame
2. Fixed anvil
3. Spindle
4. Locking lever
5. Sleeve
6. Thimble
7. Ratchet
3) MEASUREMENT
b) Micrometer - Procedures in using Micrometer
Step 1 - Position object to be measured
Position the object on the anvil, that is, the fixed
measuring face of the micrometer.

Step 2 - Clamp object between anvil and spindle

Rotate the thimble using the ratchet speeder until
the spindle is close to the object.

Step 3 - Read the measurement

Read the measurement indicated on the
scale.
3) MEASUREMENT
b) Micrometer - Reading the Micrometer
measurement

23 whole divisions are uncovered = 23 mm

0 divisions are uncovered = 0.0 mm
15 x 0.01 millimeter divisions line up on the thimble = 0.15 mm

reading equals 23.15 millimeters

3) MEASUREMENT
b) Micrometer - Reading the Micrometer
measurement

15 whole divisions are uncovered = 15 mm

0.5 divisions are uncovered = 0.5 mm
13 x 0.01 millimeter divisions line up on the thimble = 0.13 mm

reading equals 15.63 millimeters.

3) MEASUREMENT
b) Micrometer - Reading the Micrometer
measurement

18 whole divisions are uncovered =18mm

0.5 millimeters division is uncovered = 0.5 mm
10 x 0.01 millimeter divisions line up on the thimble = 0.10 mm

reading equals 18.60 millimeters

3) MEASUREMENT
b) Micrometer - Reading the Micrometer
measurement
3) MEASUREMENT
b) Micrometer - Reading the Micrometer
measurement
3) MEASUREMENT
b) Micrometer - Reading the Micrometer
measurement
3) MEASUREMENT
b) Micrometer - Reading the Micrometer
measurement
3) MEASUREMENT

c) Vernier Caliper - parts

1) Inside jaws
2) Frame
3) Main scale
4) Vernier scale
5) Sliding jaw
6) Outside jaws.
3) MEASUREMENT

c) Vernier Caliper - basic principle

Vernier calliper reading , total :-
1) Checked if have zero error
2) Main scale measurement
3) Vernier scale measurement
3) MEASUREMENT

c) Vernier Caliper - basic principle

i. Checked zero error ( + ve or –ve error)
ii. Positive Error: zero of vernier lies right
to the zero of the main scale, the error
is positive and the zero correction is
negative. For example,
Zero error = + 2 divisions.
Zero correction = − 3 × (LC) = − 3 × 0.01
cm = − 0.03 cm
i. Negative Error: zero of the vernier lies
left to the zero of the main scale, the
error is negative and the zero correction
is positive. For example
Zero error = − (10 − 8) = − 2 divisions
Zero correction = +2 × 0.01 cm = +0.02
cm
3) MEASUREMENT

c) Vernier Caliper - basic principle

(Vernier scale division)
3) MEASUREMENT

c) Vernier Caliper - reading

3) MEASUREMENT

c) Vernier Caliper - reading

3) MEASUREMENT

c) Vernier Caliper - reading

REVIEW
1) Name the parts of the Vernier caliper.

2) State the reading of Vernier caliper.

REVIEW
3) State the reading of Vernier caliper.
REVIEW
4) State the reading of micrometer.
REVIEW
5) State the reading of Vernier caliper and micrometer.
REVIEW
6) List FIVE (5) types of hand tools which are commonly used in a workshop.
7) Explain THREE (3) advantages and TWO (2) disadvantages using a Vernier
caliper.
8) State FOUR (4) types of gauges in a mechanical engineering workshop.
9) State and explain TWO (2) techniques in a filling process.
10) Clarify FIVE (5) approaches of file care.
11) List TWO (2) types of micrometer and their application.
12) State TWO (2) differences between a Vernier caliper and micrometer.
13) Name THREE (3) marking tools used in mechanical engineering workshop
and list the function of each marking tool.
14) Explain the function of micrometer.
15) Explain TWO (2) advantages and disadvantages of using a Vernier caliper.